U.S. patent application number 16/133147 was filed with the patent office on 2020-03-05 for pump assemblies and pumping systems incorporating pump assemblies.
This patent application is currently assigned to National Oilwell Varco, L.P.. The applicant listed for this patent is National Oilwell Varco, L.P.. Invention is credited to Adrian Marica.
Application Number | 20200072201 16/133147 |
Document ID | / |
Family ID | 69639723 |
Filed Date | 2020-03-05 |
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United States Patent
Application |
20200072201 |
Kind Code |
A1 |
Marica; Adrian |
March 5, 2020 |
PUMP ASSEMBLIES AND PUMPING SYSTEMS INCORPORATING PUMP
ASSEMBLIES
Abstract
Pump assemblies and pumping systems incorporating the pump
assemblies are disclosed. In an embodiment, the pump assembly
includes a power end including an output shaft having an output
shaft axis. In addition, the pump assembly includes a fluid end
including a piston configured to reciprocate to pressurize the
working fluid. Further, the pump assembly includes a transmission
coupled to each of the power end and the fluid end. The
transmission includes a carriage coupled to the piston and a
pivoting arm pivotably coupled to the carriage at a first
connection about a first pivot axis. The first pivot axis extends
in a perpendicular direction to a direction of the output shaft
axis, and rotation of the output shaft about the output shaft axis
is configured to cause the pivoting arm to pivot about the first
pivot axis at the first connection and to cause the carriage to
reciprocate
Inventors: |
Marica; Adrian; (Cypress,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
National Oilwell Varco, L.P. |
Houston |
TX |
US |
|
|
Assignee: |
National Oilwell Varco,
L.P.
Houston
TX
|
Family ID: |
69639723 |
Appl. No.: |
16/133147 |
Filed: |
September 17, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62723885 |
Aug 28, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 21/00 20130101;
F04B 1/14 20130101; F04B 53/109 20130101; F04B 23/06 20130101; F04B
1/02 20130101; F04B 9/02 20130101; F04B 15/02 20130101; F04B 19/22
20130101; F04B 1/143 20130101; F04B 9/042 20130101 |
International
Class: |
F04B 1/14 20060101
F04B001/14; F04B 9/04 20060101 F04B009/04; F04B 23/06 20060101
F04B023/06; F04B 19/22 20060101 F04B019/22 |
Claims
1. A pump assembly for pressurizing a working fluid, the pump
assembly comprising: a base; a power end mounted to the base, the
power end comprising an output shaft having an output shaft axis; a
fluid end mounted to the base, the fluid end comprising a piston
configured to reciprocate within the fluid end to pressurize the
working fluid; and a transmission coupled to each of the power end
and the fluid end wherein the transmission comprises: a carriage
coupled to the piston and reciprocally coupled to the base; and a
pivoting arm pivotably coupled to the carriage at a first
connection about a first pivot axis, wherein the first pivot axis
extends in a direction that is perpendicular to a direction of the
output shaft axis; wherein rotation of the output shaft about the
output shaft axis is configured to cause the pivoting arm to pivot
about the first pivot axis at the first connection and to cause the
carriage to reciprocate relative to the base.
2. The pump assembly of claim 1, wherein the transmission further
comprises: an offset shaft coupled to the output shaft, wherein the
offset shaft comprises an offset shaft axis that is disposed at a
non-zero angle .theta. relative to the output shaft axis; and a
linking assembly coupled to the offset shaft assembly and the base;
wherein the pivoting arm is pivotably coupled to the linking
assembly at a second connection about a second pivot axis, wherein
the second connection is spaced from the first connection along the
pivot arm and the second pivot axis is parallel to and radially
offset from the first pivot axis; and wherein rotation of the
output shaft about the output shaft axis is configured to cause the
offset shaft to orbit about the output shaft axis and to cause the
pivoting arm to pivot about the second pivot axis at the second
connection.
3. The pump assembly of claim 2, wherein the angle .theta. is
between 0 and 90.degree..
4. The pump assembly of claim 3, wherein the transmission further
comprises an offset collar member having a first through bore and a
second throughbore spaced from the first throughbore, wherein the
output shaft is received within the first throughbore; wherein a
first end of the offset shaft is received within the second
throughbore; and wherein rotation of the output shaft about the
output shaft axis is configured to cause the offset collar member
to rotate about the output shaft axis and to cause the offset shaft
to rotate within the second throughbore of the offset collar
member.
5. The pump assembly claim 2, wherein the linking assembly
comprises a universal joint assembly, the universal joint assembly
comprising: a first gimbal member coupled to the offset shaft; and
a second gimbal member pivotably coupled to the first gimbal member
and pivotably coupled to the pivoting arm at the second
connection.
6. The pump assembly of claim 5, wherein the first gimbal member
comprises a first body and a pair of parallel projections extending
from the first body; wherein second gimbal member comprises second
body, a first pair of shafts, and a second pair of shafts, wherein
the first pair of shafts and the second pair of shafts extend
outward from the second body; wherein the first pair of shafts are
pivotably coupled to the base; and wherein the second pair of
shafts are pivotably coupled to the projections of the first gimbal
member.
7. The pump assembly of claim 6, wherein the first pair of shafts
is aligned along a third pivot axis, wherein the second pair of
shafts is aligned along a fourth pivot axis, and wherein the third
axis is orthogonal to the fourth axis.
8. The pump assembly of claim 7, wherein the fourth pivot axis
extends in a direction that is perpendicular to the direction of
the output shaft axis.
9. The pump assembly of claim 2, wherein the linking assembly
comprises: a ball coupled to the base; and a clamp assembly
disposed about the ball, wherein the clamp assembly is configured
to pivot omni-directionally about the ball.
10. The pump assembly of claim 9, wherein the clamp assembly is
mounted to the offset shaft and pivotably coupled to the pivoting
arm at the second connection.
11. A pumping system, comprising: a suction manifold; a discharge
manifold; and a plurality of pump assemblies configured to draw a
working fluid from the suction manifold, pressurize the working
fluid, and deliver the pressurized working fluid to the discharge
manifold; wherein each of the plurality of pump assemblies
comprises: a base; a power end mounted to the base, the power end
comprising an output shaft having an output shaft axis; a fluid end
mounted to the base, the fluid end comprising a piston configured
to reciprocate within the fluid end to pressurize the working
fluid; and a transmission coupled to each of the power end and the
fluid end wherein the transmission comprises: a carriage coupled to
the piston and reciprocally coupled to the base; and a pivoting arm
pivotably coupled to the carriage at a first connection about a
first pivot axis, wherein the first pivot axis extends in a
direction that is perpendicular to a direction of the output shaft
axis; wherein rotation of the output shaft about the output shaft
axis is configured to cause the pivoting arm to pivot about the
first pivot axis at the first connection and to cause the carriage
to reciprocate relative to the base.
12. The pumping system of claim 11, wherein the transmission of
each pump assembly further comprises: an offset shaft coupled to
the output shaft, wherein the offset shaft comprises an offset
shaft axis that is disposed at a non-zero angle .theta. relative to
the output shaft axis; and a linking assembly coupled to the offset
shaft assembly and the base; wherein the pivoting arm is pivotably
coupled to the linking assembly at a second connection about a
second pivot axis, wherein the second connection is spaced from the
first connection along the pivot arm and the second pivot axis is
parallel to and radially offset from the first pivot axis; and
wherein rotation of the output shaft about the output shaft axis is
configured to cause the offset shaft to orbit about the output
shaft axis and to cause the pivoting arm to pivot about the second
pivot axis at the second connection.
13. The pumping system of claim 12, wherein the angle .theta. is
between 0 and 90.degree..
14. The pumping system of claim 13, wherein the transmission of
each pump assembly further comprises an offset collar member having
a first through bore and a second throughbore spaced from the first
throughbore, wherein the output shaft is received within the first
throughbore; wherein a first end of the offset shaft is received
within the second throughbore; and wherein rotation of the output
shaft about the output shaft axis is configured to cause the offset
collar member to rotate about the output shaft axis and to cause
the offset shaft to rotate within the second throughbore of the
offset collar member.
15. The pumping system of claim 12, wherein for each pump assembly,
the linking assembly comprises a universal joint assembly, the
universal joint assembly comprising: a first gimbal member coupled
to the offset shaft; and a second gimbal member pivotably coupled
to the first gimbal member and pivotably coupled to the pivoting
arm at the second connection.
16. The pumping system of claim 15, wherein for each pump assembly,
the first gimbal member comprises a first body and a pair of
parallel projections extending from the first body; wherein second
gimbal member comprises second body, a first pair of shafts, and a
second pair of shafts, wherein the first pair of shafts and the
second pair of shafts extend outward from the second body; wherein
the first pair of shafts are pivotably coupled to the base; and
wherein the second pair of shafts are pivotably coupled to the
projections of the first gimbal member.
17. The pumping system of claim 16, wherein for each pump assembly,
the first pair of shafts is aligned along a third pivot axis,
wherein the second pair of shafts is aligned along a fourth pivot
axis, and wherein the third axis is orthogonal to the fourth
axis.
18. The pumping system of claim 17, wherein for each pump assembly,
the fourth pivot axis extends in a direction that is perpendicular
to the direction of the output shaft axis.
19. The pumping system of claim 12, wherein for each pump assembly,
the linking assembly comprises: a ball coupled to the base; and a
clamp assembly disposed about the ball, wherein the clamp assembly
is configured to pivot omni-directionally about the ball.
20. The pumping system of claim 19, wherein for each pump assembly,
the clamp assembly is mounted to the offset shaft and pivotably
coupled to the pivoting arm at the second connection.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent
Application No. 62/723,885 filed Aug. 28, 2018, and entitled "Pump
Assemblies and Pumping Systems Incorporating Pump Assemblies,"
which is hereby incorporated herein by reference in its entirety
for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] This disclosure relates generally to systems for
pressurizing a working fluid. More particularly, some embodiments
of this disclosure relate to pumping systems that include one or
more direct drive pump assemblies for pressurizing a working fluid
for subsequent injection into a subterranean wellbore.
[0004] To form an oil or gas well, a bottom hole assembly (BHA),
including a drill bit, is coupled to a length of drill pipe to form
a drill string. The drill string is then inserted downhole, where
drilling commences. During drilling, fluid (or "drilling mud") is
circulated down through the drill string to lubricate and cool the
drill bit as well as to provide a vehicle for removal of drill
cuttings from the borehole. After exiting the bit, the drilling
fluid returns to the surface through an annulus formed between the
drill string and the surrounding borehole wall (or a casing pipe
lining the borehole wall). Mud pumps are commonly used to deliver
drilling fluid to the drill string during drilling operations. Many
conventional mud pumps are of a triplex configuration, having three
piston-cylinder assemblies driven out of phase by a common
crankshaft and hydraulically coupled between a suction manifold and
a discharge manifold. During operation of the mud pump, each piston
reciprocates within its associated cylinder. As the piston moves to
expand the volume within the cylinder, drilling fluid is drawn from
the suction manifold into the cylinder. After the piston reverses
direction, the volume within the cylinder decreases and the
pressure of drilling fluid contained with the cylinder increases.
When the piston reaches the end of its stroke, pressurized drilling
fluid is exhausted from the cylinder into the discharge manifold.
While the mud pump is operational, this cycle repeats, often at a
high cyclic rate, and pressurized drilling fluid is continuously
fed to the drill string at a substantially constant rate.
BRIEF SUMMARY
[0005] Some embodiments disclosed herein are directed to a pump
assembly for pressurizing a working fluid. In an embodiment, the
pump assembly includes a base, and a power end mounted to the base,
the power end comprising an output shaft having an output shaft
axis. In addition, the pump assembly includes a fluid end mounted
to the base, the fluid end comprising a piston configured to
reciprocate within the fluid end to pressurize the working fluid.
Further, the pump assembly includes a transmission coupled to each
of the power end and the fluid end. The transmission includes a
carriage coupled to the piston and reciprocally coupled to the
base. In addition, the transmission includes a pivoting arm
pivotably coupled to the carriage at a first connection about a
first pivot axis. The first pivot axis extends in a direction that
is perpendicular to a direction of the output shaft axis. Wherein
rotation of the output shaft about the output shaft axis is
configured to cause the pivoting arm to pivot about the first pivot
axis at the first connection and to cause the carriage to
reciprocate relative to the base.
[0006] Other embodiments disclosed herein are directed to a pumping
system. In an embodiment, the pumping system includes a suction
manifold, a discharge manifold, and a plurality of pump assemblies
configured to draw a working fluid from the suction manifold,
pressurize the working fluid, and deliver the pressurized working
fluid to the discharge manifold. Each of the plurality of pump
assemblies includes a base, a power end mounted to the base, the
power end comprising an output shaft having an output shaft axis.
In addition, each of the pump assemblies includes a fluid end
mounted to the base, the fluid end comprising a piston configured
to reciprocate within the fluid end to pressurize the working
fluid. Further, each of the pump assemblies includes a transmission
coupled to each of the power end and the fluid end. The
transmission includes a carriage coupled to the piston and
reciprocally coupled to the base, and a pivoting arm pivotably
coupled to the carriage at a first connection about a first pivot
axis. The first pivot axis extends in a direction that is
perpendicular to a direction of the output shaft axis. Wherein
rotation of the output shaft about the output shaft axis is
configured to cause the pivoting arm to pivot about the first pivot
axis at the first connection and to cause the carriage to
reciprocate relative to the base.
[0007] Embodiments described herein comprise a combination of
features and characteristics intended to address various
shortcomings associated with certain prior devices, systems, and
methods. The foregoing has outlined rather broadly the features and
technical characteristics of the disclosed embodiments in order
that the detailed description that follows may be better
understood. The various characteristics and features described
above, as well as others, will be readily apparent to those skilled
in the art upon reading the following detailed description, and by
referring to the accompanying drawings. It should be appreciated
that the conception and the specific embodiments disclosed may be
readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes as the disclosed
embodiments. It should also be realized that such equivalent
constructions do not depart from the spirit and scope of the
principles disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a detailed description of various exemplary embodiments,
reference will now be made to the accompanying drawings in
which:
[0009] FIG. 1 is a schematic view of an embodiment of a pumping
system according to at least some embodiments;
[0010] FIG. 2 is a schematic view of an embodiment of a pump
assembly for use within the pumping system of FIG. 1 according to
at least some embodiments;
[0011] FIG. 3 is a schematic, partial, side cross-sectional view of
the transmission of the pump assembly of FIG. 2;
[0012] FIGS. 4 and 5 are partial perspective views of the
transmission of the pump assembly of FIG. 2;
[0013] FIG. 6 is a partial perspective view of the transmission of
another pump assembly for use within the pumping system of FIG. 1
according to at least some embodiments; and
[0014] FIG. 7 is a schematic, partial cross-sectional view of the
transmission of FIG. 6.
DETAILED DESCRIPTION
[0015] The following discussion is directed to various exemplary
embodiments. However, one of ordinary skill in the art will
understand that the examples disclosed herein have broad
application, and that the discussion of any embodiment is meant
only to be exemplary of that embodiment, and not intended to
suggest that the scope of the disclosure, including the claims, is
limited to that embodiment.
[0016] The drawing figures are not necessarily to scale. Certain
features and components herein may be shown exaggerated in scale or
in somewhat schematic form and some details of conventional
elements may not be shown in interest of clarity and
conciseness.
[0017] In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. . ." Also, the term "couple" or "couples" is intended to mean
either an indirect or direct connection. Thus, if a first device
couples to a second device, that connection may be through a direct
connection of the two devices, or through an indirect connection
that is established via other devices, components, nodes, and
connections. In addition, as used herein, the terms "axial" and
"axially" generally mean along or parallel to a given axis (e.g.,
central axis of a body or a port), while the terms "radial" and
"radially" generally mean perpendicular to the given axis. For
instance, an axial distance refers to a distance measured along or
parallel to the axis, and a radial distance means a distance
measured perpendicular to the axis. As used herein, the terms
"gimbal," "gimbal member," and the like, refers to a pivoted
support that allows the rotation of an object about an axis.
[0018] As previously described above, mud pumps, including multiple
piston-cylinder assemblies driven out of phase by a common
crankshaft, are typically used to deliver drilling fluid to a drill
string during drilling operations. These pumps have a set footprint
and configuration. Thus, if it is desired to increase the flow rate
of drilling fluid above what the piston-cylinder assemblies can
deliver, an additional mud pump must be installed, or another mud
pump must be designed and fabricated that includes the appropriate
number of piston-cylinder assemblies to provide the desired flow
rate of drilling fluid. As a result, these conventional mud pumps
are not easily adaptable to the changing specifications and needs
of many drilling applications. In addition, adequate space must be
provided at the drill site to accommodate not only the size of
these mud pumps but also the set footprint thereof.
[0019] Accordingly, embodiments disclosed herein include pumping
systems for pressurizing a working fluid (e.g., drilling fluid
injected into a subterranean wellbore), that include a plurality of
modular pump assemblies. As a result, the number and specific
arrangement of the modular pump assemblies may be altered as
desired to accommodate a specific flow rate, pressure, and spacing
requirements of the drilling operation.
[0020] Referring now to FIG. 1, a pumping system 10 for
pressurizing a working fluid (e.g., drilling mud) is shown. Pumping
system 10 generally includes a suction manifold 12, a discharge
manifold 14, and a plurality of pumping assemblies 100. Suction
manifold 12 is in fluid communication with a working fluid source
(e.g., a mud pit), and discharge manifold 14 is in fluid
communication with a fluid delivery point (e.g., a central
throughbore of a drill string). Each pump assembly 100 is coupled
to suction manifold 12 with a corresponding suction line 16, and is
coupled to discharge manifold 14 with a corresponding discharge
line 18, such that each pump assembly 100 is configured to receive
fluids from suction manifold 12 via the corresponding suction line
16, and emit pressurized fluid to one of the discharge manifolds 14
via the corresponding discharge line 18.
[0021] Each pump assembly 100 includes a power end 109, a
transmission 120, and a fluid end 60. In this embodiment, power end
109 comprises a motor 110 including an output shaft 112. Motor 110
may be any suitable motor or driver that is configured to actuate
(e.g., rotate) an output shaft 118, such as, for example, an
electric motor, hydraulic motor, internal combustion engine,
turbine, etc. In this embodiment, motor 110 comprises an electric
motor 110.
[0022] Transmission 120 comprises any suitable mechanism that is
configured to translate the output from motor 110 into an input
drive for fluid end 60. For example, in this embodiment, motor 110
drives the rotation of output shaft 118, and transmission 120 is
configured to convert the rotational motion of output shaft 118
into a reciprocal motion for driving a piston 64 within fluid end
60 (note: in some embodiments, pistons 64 may be replaced with a
plunger or other reciprocating member, thus, the term "piston" is
used herein to include various designs of pistons, plungers,
bladders, and other suitable reciprocating members for use within
fluid end 60). While some specific embodiments of transmission 120
are discussed below, it should be appreciated that transmission 120
may comprise any suitable arrangement of gears, cams, sliders,
carriages, or other components to affect the desired motion
conversion between motor 110 and fluid end 60.
[0023] Fluid end 60 defines a chamber 62 that receives piston 64
therein. Piston 64 is coupled to transmission 120 and is configured
to reciprocate within chamber 62 and sealingly engage with the
inner walls of chamber 62 to facilitate the pressurization and flow
of a working fluid (e.g., drill mud) therein. Fluid end 60 includes
a suction valve 15 and a discharge valve 17. Suction valve 15 is
configured to allow fluid flow into chamber 62 via suction line 16
when piston 64 withdrawn from chamber 62 (e.g., toward transmission
120) and the pressure within chamber 62 falls below a first
predetermined level, but to prevent fluid from flowing out of
chamber 62 into line 16. Discharge valve 17 is configured to allow
fluid to flow out of chamber 62 into discharge line 18 when piston
64 is advanced into chamber 62 (e.g., away from transmission 120)
and the pressure within chamber 62 rises above a second
predetermined level, but to prevent fluid from flowing into chamber
62 from discharge line 18. While valves 15, 17 are merely shown
schematically in FIG. 1, it should be appreciated that valves 15,
17 may be the same or similar to those disclosed in U.S. Pat. Nos.
8,220,496 and/or 8,714,193, the entire contents of each being
incorporated herein by reference for all purposes.
[0024] Referring still to FIG. 1, pumping system 10 includes a
plurality of suction valves 22 and discharge valves 24. Each of the
suction valves 22 is disposed along one of the suction lines 16 and
each of the discharge valves 24 is disposed along one of the
discharge lines 18. Each of the valves 22, 24 is coupled to a
central controller 50 through a corresponding connection 58, which
may be any suitable wired or wireless connection for communicating
signals, such as, for example a cable, wire, fiber optic line,
radio frequency (RF) connection, a WIFI connection, BLUETOOTH.RTM.
connection, short wave communication signal, acoustic connection,
etc. Controller 50 may include a processor and a memory, wherein
each of the processor and memory may comprise one or more
electrical circuits. The memory includes computer readable
instructions for execution by the processor to provide all of the
functionality of controller 50 disclosed herein. Each of the valves
22, 24 also includes a pair of sensors 26, 28 that are configured
to sense whether the corresponding valve (e.g., valve 22, 24) is
opened or closed (i.e., whether the valves 22, 24 are in an open
position or a closed position, respectively). Specifically, one
sensor 26 is configured to sense when the corresponding valve is in
the open position (to thereby allow fluid to flow freely along the
corresponding line 16, 18), and the other sensor 28 is configured
to sense when the corresponding valve is in the closed position (to
thereby prevent or restrict fluid flow along the corresponding line
16, 18). The sensors 26, 28 are each configured to communicate with
controller 50 via connections 58 so that controller 50 may know
whether each valve 16, 18 is in the open or closed position. In
this embodiment, controller 50 is coupled to an external device 51,
which may comprise, for example, a display (e.g., a computer
monitor) that is further configured to display information (e.g., a
graphic) that shows which of the valves 22, 24 is in the open
position and which of the valves 22, 24 is in the closed position.
In addition, in some embodiments, controller 50 may be configured
to actuate each of the valves 22, 24 between the open and closed
positions.
[0025] Each pump assembly 100 includes a plurality of sensors that
communicate with controller 50 to facilitate and optimize the
control thereof during operations. For example, in this embodiment,
each pump assembly 100 includes a rotary sensor 56 coupled to motor
110 and configured to measure or determine the rotational speed
and/or direction of the output shaft 118. In addition, each pump
assembly 100 includes a linear displacement or position sensor 54
coupled to transmission 120 or fluid end 60 (in this embodiment,
sensor 54 is coupled to transmission 120) and configured to measure
or determine the position or displacement of piston 64 relative to
some fixed point. Further, each pump assembly 100 includes a
pressure sensor 52 coupled to fluid end 60 and configured to
measure a pressure of the chamber 62 during operations. Each of the
sensors 52, 54, 56 are coupled to controller 50 through a
corresponding connection 58, where connections 58 between sensors
52, 54, 56 and controller 50 are configured the same as the
connections 58 between sensors 26, 28 and controller 50.
[0026] In some embodiments, controller 50 drives motors 110 so that
the pistons 64 of pump assemblies 100 operate in phase with one
another but with a continuously variable angle or timing between
them (e.g., via controller 50) to produce a relatively constant
flow of pressurized working fluid to discharge manifold.
Specifically, in this embodiment, because pumping system 10
includes two pump assemblies, the pistons 64 are operated
approximately 180.degree. out of phase with one another (i.e., so
that as each piston 64 reaches its maximum extension during a
discharge stroke, the other piston reaches its minimum extension
during a suction stroke). However, it should be appreciated that
the phase difference between pistons 64 of pump assemblies 100 will
change as the number of pump assemblies 100 is increased or
deceased (e.g., if three pump assemblies 100 are used, each piston
64 is operated approximately 120.degree. out of phase with the
other pistons 64). In some embodiments, controller 110 verifies
and/or maintains the proper timing of the strokes of pistons 64
(e.g., to maintain the desired phase separation of pistons 64) by
sensing the motor rotational speed and direction via rotary sensors
56 and correlating the measured rotational speed to the position of
piston 64 via linear displacement or position sensors 54.
[0027] For each pump assembly 100, as motor 110 drives rotation of
output shaft 118, transmission 120 converts this rotational motion
into a reciprocating motion so that piston 64 is repetitively
driven between a suction stroke and a discharge stroke within
chamber 62. During a suction stroke of piston 64, piston 64 is
withdrawn toward transmission 120 such that the pressure within
chamber 62 is reduced to draw in working fluid from line 16 via
suction valve 15. In addition, during a suction stroke, working
fluid is prevented from flowing into chamber 62 by discharge valve
17. Conversely, during a discharge stroke, piston 64 is driven or
extended away from transmission 120, such that the pressure within
chamber 62 is increased to force fluid out of chamber 62 into
discharge line 18 via discharge valve 17. In addition, during a
discharge stroke, working fluid is prevented from flowing out of
chamber 62 into suction line 16 by suction valve 15.
[0028] Specific embodiments of pump assemblies 100 will now be
described in more detail. It should be appreciated that any one or
more of these embodiments discussed below may be incorporated into
pumping system 10 of FIG. 1.
[0029] Referring now to FIG. 2, embodiment of pump assembly 100 is
shown. As previously described, pump assembly 100 includes power
end 109, transmission 120, and fluid end 60. In some embodiments,
fluid end 60 may be the same as the fluid end embodiments disclosed
in WO2017/123656. Pump assembly 100 may be referred to as a modular
unit in that the components of pump assembly 100 may be easily
disassembled, assembled, and/or interchanged with other similar
components. This may facilitate transportation, design,
maintenance, and replacement of pump assembly 100 and the
components thereof during operations.
[0030] In the embodiment of FIG. 2, power end 109 includes both
motor 110 and a reducer 114. The reducer 114 is coupled between a
shaft 112 of motor 110 and transmission 120. In particular, reducer
114 includes a reducer gear assembly 116 that is coupled to shaft
112 and an output shaft 118 that engages with transmission 120.
Thus, in this embodiment output shaft 118 may be referred to as an
"output shaft" of power end 109. In this embodiment, reducer gear
assembly 116 is configured to rotate output shaft 118 a fraction of
the number of times that shaft 112 rotates. Specifically, in this
embodiment, reducer gear assembly 116 is configured to rotate
output shaft 118 one time for every sixteen rotations of shaft 112
of motor 110. Thus, reducer gear assembly 116 works to reduce the
rotational rate (e.g., in rotations per minute (rpm)) of shaft 112
of motor 110 and to increase the torque supplied to transmission
120 from that generated by motor 110 alone. It should be
appreciated, that in some embodiments, no reducer 114 is included
and shaft 112 of motor 110 couples directly to transmission 120
(such that shaft 112 may be referred to as an "output shaft" of
power end 109 in these embodiments). In other embodiments, reducer
gear assembly 116 is incorporated into motor 110 itself such that
reducer gear assembly 116 would be disposed within an outer housing
of motor 110 and output shaft 118 of reducer 114 would effectively
be the output shaft of motor 110 itself.
[0031] Referring still to FIG. 2, pump assembly 100 also includes a
base or frame 101 to support power end 109, transmission 120, and
fluid end 60. In this embodiment, base 101 includes a first or
motor base 102, and a second or transmission base 103 coupled to
motor base 102. Motor base 102 supports power end 109 including
motor 112 and reducer 114, while transmission base 103 supports
transmission 120 and fluid end 60.
[0032] Motor base 102 comprises a first end 102a, and a second end
102b that is opposite first end 102a. Similarly, transmission base
103 includes a first end 103a, and a second end 103a that is
opposite first end 103a. Motor base 102 is coupled to the first end
103a of transmission base 103 at second end 102b via one or more
mounting plates 106 that are disposed on first end 103a of
transmission base 103. Mounting plates 106 each include a plurality
of holes or apertures 107 for receiving bolts or other connection
members (e.g., screws, pins, rivets, etc.) therethrough. In
addition, transmission base 103 includes a pair of vertically
oriented support extensions 105 at second end 103b that form a
frame for supporting fluid end 60 on base 103. In this embodiment,
a mounting plate 108 is coupled to extensions 105 and fluid end 60
is mounted to plate 107. However, in other embodiments, fluid end
60 may be secured to extensions 105 without a mounting plate 108
(e.g., fluid end 60 may be secured to extensions 105 via separate
bracket or other support member or may be directly mounted to
extensions 105 without utilizing a separate support or mounting
member).
[0033] Power end 109 may be decoupled from transmission 120 and
bases 102, 103 may also be decoupled at mounting plates 106 so that
power end 109 may be transported or maneuvered separately from
transmission 120 and fluid end 60 on base 103. In addition, fluid
end 60 may be decoupled from base 103 and moved, repaired, replaced
via the connection at plate 108 and beams 105. Therefore, bases
102, 103 help to facilitate the modularity of pump assembly 100 by
providing relatively simple attachment points between the
components (e.g., specifically between motor 110 and reducer 114
and transmission 120, and between transmission 120 and fluid end
60).
[0034] Referring now to FIGS. 2 and 3, transmission 120 provides a
linkage between power end 109 and the fluid end 60 to drive
reciprocation of piston 64 within fluid end 60 (e.g., see also FIG.
1) to pressurize a working fluid as previously described above.
Specifically, transmission 120 converts the rotational motion of
output shaft 118 of reducer 114 (or output shaft of motor 112) into
a reciprocal motion of the piston 64 within fluid end 60. In this
embodiment, transmission 120 includes an offset shaft assembly 122
coupled to output shaft 118, a carriage 150 coupled to the piston
64, a pivoting arm assembly 141 coupled to the carriage 150, and a
linking assembly 130 coupled between the offset shaft assembly 122
and pivoting arm assembly 141.
[0035] Carriage 150 is coupled to piston 64 that is reciprocally
disposed within fluid end 60 as previously described (see also FIG.
1). During operations, carriage 150 is driven to reciprocate
relative to transmission frame 103 by power end 109 via offset
shaft assembly 122, linking assembly 130, and pivoting arm assembly
141. As a result, the reciprocation of carriage 150 drives
reciprocation of the piston 64. As shown in FIG. 3, the
reciprocation of carriage 150 may be facilitated and supported by
one or more tracks 156 that are mounted to frame 103 (note: frame
103 is not shown in FIG. 3 so as not to unduly complicate the
figure). In some embodiments, carriage 150 may be similar to the
carriages (or carriage assemblies) described in WO2017/123656.
[0036] Referring again to FIG. 2, offset shaft assembly 122
includes an offset collar member 123 and a shaft 128. Offset collar
member 123 is an elongate member having a first end 123a, a second
end 123b opposite the first end 123a, a first throughbore 124, and
a second throughbore 125. As shown in FIG. 2, first throughbore 124
is disposed more proximate to first end 123a than second end 123b,
and second throughbore 125 is disposed more proximate to second end
123b than first end 123a.
[0037] Second throughbore 125 receives a first end 128a of shaft
128, and first throughbore 124 receives an end of output shaft 118
of reducer 114. In this embodiment output shaft 118 is mounted
within throughbore 124 such that no relative rotation between shaft
118 and throughbore 124 is allowed (i.e., such that offset collar
member 123 rotates with output shaft 118 during operation). In some
embodiments, shaft 118 and throughbore 124 may include a
corresponding keyed or splined connection. In other embodiments,
output shaft 118 may include one or more facets or planar surfaces
that interact with corresponding planar surfaces within throughbore
124 (e.g., output shaft 118 and throughbore 124 may include
polygonal cross-sections).
[0038] In addition, in the embodiment of FIG. 2, offset collar
member 123 includes a connector 126 at first end 123a that forms a
portion (e.g., half) of first throughbore 124. Connector 126 may be
secured to the rest of offset collar member 123 about shaft 118 via
a plurality of bolts 127 (or other suitable connection members
(e.g., screws, pins, rivets, etc.).
[0039] Shaft 128 is an elongate member that includes first end 128a
and a second end 128b opposite first end 128a. First end 128a of
shaft 128 is received within second throughbore 125 of offset
collar member 123, as previously described, such that shaft 128 may
rotate freely relative to offset collar member 123 during
operations. For example, one or more bearings (e.g., radial or
spherical bearings--not shown) may be disposed within throughbore
125 to facilitate the relative rotation between shaft 128 and
collar member 123.
[0040] Referring again to FIGS. 2 and 3, in this embodiment, offset
collar member 123 (or at least a portion thereof) extends outward
from a central axis 115 of output shaft 118 at an angle (not
specifically marked in FIG. 2) that is between 0.degree. and
90.degree. (i.e., offset collar member 123 extends at an acute
angle to axis 115 of output shaft 118). Axis 115 may be referred to
herein as the offset shaft axis 115. Thus, when first end 128a of
shaft 128 is received through second throughbore 125, shaft 128
extends along an axis 129 that is disposed at an angle .theta. to
axis 115 of output shaft 118. The angle .theta. may range between
0.degree. and 90.degree.. In some embodiments, the angle .theta.
may range from 10.degree. to 50.degree., or from 15.degree. to
23.degree.. In other embodiments, offset collar member 123 may
extend radially outward (e.g., at 90.degree.) from axis 115 of
shaft 118.
[0041] During operations, as output shaft 118 is rotated about axis
115, offset collar 123 is also caused to rotate about axis 115 at
throughbore 124 (e.g., due to the connection between shaft 118 and
throughbore 124 as previously described above). As a result, second
throughbore 125 and first end 128a of shaft 128 are also caused
rotate about axis 115 such that axis 129 of shaft 128 traces a cone
(not shown) that has sides extending at the angle .theta. relative
to axis 115.
[0042] Referring still to FIGS. 2 and 3, as previously described
linking assembly 130 is coupled between each of the offset shaft
assembly 122 and carriage 150. In this embodiment, linking assembly
130 comprises a universal joint (U-joint) assembly 121 (or more
simply "U-joint 121"), that is mounted to second end 128b of offset
shaft 128 and is pivotably coupled to carriage 150 via a pivoting
arm assembly 141.
[0043] U-joint 121 includes a first gimbal member 132 and a second
gimbal member 138 pivotably coupled to one another. First gimbal
member 132 includes a base 134 and a pair of parallel extensions
136 extending from base 134 that define a recess 133 therebetween.
Second end 128b of shaft 128 is engaged with base 134 such that
first gimbal member 132 may not rotate relative to shaft 128. Any
suitable connection may be used between first gimbal member 132 and
shaft 128, such as, for example, threads, a flanged coupling,
welding, clamps, etc. Each of the extensions 136 includes a
throughbore 131 extending therethrough that are aligned with one
another along a pivot axis 135' extending across recess 133.
[0044] Second gimbal member 138 includes a central body 138a, a
first pair of shafts 137a, 137b, and a second pair of shafts 139a,
139b. Each of the shafts 137a, 137b extend from a first pair of
opposing sides of body 138a and each of the shafts 139a, 139b
extend from a second pair of opposing sides of body 138a. Central
body 138a is received within recess 133 and the second pair of
shafts 139a, 139b are pivotably inserted through throughbores 131
of projections 136, such that shafts 139a, 139b are aligned along
pivot axis 135'. Thus, body 138a of second gimbal member 138 may
freely pivot about pivot axis 135' relative to first gimbal member
132 due to the coupling between throughbores 131 and shafts 139a,
139b. Any suitable bearing or similar coupling may be used between
throughbores 131 and shafts 139a, 139b (e.g., radial and/or
spherical bearings) to support the relative rotation therebetween.
However, shafts 139a, 139b may be secured within throughbores 131,
such that axial movement of second gimbal member 138 relative to
first gimbal member 132 along pivot axis 135' is prevented (or at
least restricted).
[0045] As best shown in FIG. 2, the first pair of shafts 137a, 137b
of second gimbal member 138 are pivotably received within a pair of
shaft mounts 145 mounted to transmission base 103 such that shafts
137a, 137b are disposed along a pivot axis 135'' that is orthogonal
to pivot axis 135'. Only one shaft mount 145 is shown in FIG. 2
(i.e., the other shaft mount 145 and the associated portion of base
103 for supporting the shaft mount 145 is hidden in FIG. 2 so as to
more clearly show the components of linking assembly 130). However,
it should be appreciated that the un-depicted shaft mount 145 (and
the portion of base 103 supporting shaft mount 145) would be the
same as the depicted shaft mount 145 (and base support) in FIG. 2,
and would be disposed on the opposing side of the linking assembly
130 from the depicted shaft mount (and base support). Body 138a of
second gimbal member 138 may freely pivot relative to mounts 145
about pivot axis 135''. In addition, due to the connection between
shafts 139a, 139b and throughbores 131 in projections 136, first
gimbal member 132 and second gimbal member 138 may both pivot
together about pivot axis 135'' during operations.
[0046] Referring still to FIGS. 2 and 3, pivoting arm assembly 141
includes a sleeve member 140 and a pivoting arm 144. Sleeve member
140 includes a sleeve 142 that receives shaft 139b extending from
body 138a. Pivoting arm 144 includes a first end 144a, a second end
144b opposite first end 144a, and a pair of connecting arms 146
extending from first end 144a that form a recess 147 extending
therebetween. First end 144a of pivoting arm 144 is pivotably
coupled sleeve member 140, while second end 144b of pivoting arm
144 is pivotably coupled to carriage 150. In particular, a first
connection (e.g., a pinned coupling) 148 extends through each of
the pivoting arm 144 and carriage assembly 152 proximate second end
144b. In addition, sleeve member 140 is received within recess 147
between arms 146 and a second connection (e.g., a pinned
connection) 149 extends between arms 146 and sleeve member 140.
Thus, pivoting arm 144 may pivot relative to carriage 150 about a
pivot axis 143'' at first connection 148, and pivoting arm 144 and
sleeve member 140 may pivot relative to one another about a pivot
axis 143' at second connection 149. In addition, as pivoting arm
144 and sleeve member 140 pivot relative to one another about axis
143' about second connection 149, sleeve 142 (and shaft 139b
disposed therein) may be received within recess 147. Pivot axes
143', 143'' are parallel and radially offset from one another. In
addition, each of the pivot axes 143', 143'' are parallel to and
radially offset from pivot axis 135'', and each of the pivot axes
143', 143'' extending in directions that are perpendicular to the
direction of axis 135' and the direction of output shaft axis 115.
Moreover, each of the axes 143', 143'', 135'' lie within vertically
oriented planes that extend perpendicularly to a vertically
oriented plane containing the output shaft axis 115 (assuming that
base 101 is level on a support surface).
[0047] Referring now to FIGS. 2-5, during operations, output shaft
118 of reducer 116 is rotated about axis 115 by motor 110 as
previously described, which further causes offset collar member 123
to rotate about axis 115. The rotation of collar member 123 about
axis 115 further causes shaft 128 to orbit about axis 115 and
thereby trace a cone as previously described. The orbit of shaft
128 about axis 115 causes first gimbal member 132 to reciprocally
pivot relative to second gimbal member 138 about pivot axis 135'
(via the relative pivoting between shafts 139a, 139b and
throughbores 131 in extensions 136 as previously described above).
Simultaneously, the orbit of shaft 128 causes first and second
gimbal members 132, 138 to reciprocally pivot together about pivot
axis 135''.
[0048] As gimbal members 132, 138 pivot about axis 135'', sleeve
member 140 is driven to reciprocally pivot about axis 143' relative
to pivoting arm 144 due to the engagement between sleeve 142 and
shaft 139b, at second connection 149. In addition, the pivoting of
gimbal member 132, 138 about pivot axis 135'' also causes pivoting
arm 144 to pivot relative to carriage 150 about pivot axis 143'',
at first connection 148. As best shown in the sequence between
FIGS. 4 and 5, the reciprocal pivoting of gimbal members 132, 138
about axis 135'' and the simultaneous reciprocal pivoting of sleeve
member 140 and pivoting arm 144 about connections 149, 148
ultimately causes a reciprocal translation of second end 144b of
pivoting arm 144 along a direction 151 that is parallel to and
radially offset from axis 115. This axial translation of second end
144b of pivoting arm 144 along direction 151 also causes or drives
reciprocation of carriage 150 along track 156 mounted to base 103
in the direction 151. Because carriage 150 is coupled to the piston
64 (which is disposed within fluid end 60--see FIG. 1), the
reciprocation of carriage 150 along direction 151 drives the
reciprocation of piston 64 within the fluid end 60 to provide a
flow of pressurized working fluid from pump assembly 100 as
previously described above.
[0049] Referring now to FIGS. 6 and 7, another embodiment of
linking assembly (which is identified as linking assembly 230
herein) is shown for use within pump assembly 100 in place of
linking assembly 130. Many components of linking assembly 230 are
the same as those found in linking assembly 130, and thus, like
components are identified with like reference numerals and the
description below will focus on the components of linking assembly
230 that are different from linking assembly 130 (see FIG. 3).
[0050] In particular, linking assembly 230 includes a spherical
connection assembly 232 in place of U-Joint 121. Spherical
connection assembly 232 is mounted to second end 128b of offset
shaft 128 and is pivotably coupled to carriage 150 via the pivoting
arm assembly 141 in substantially the same manner as linking
assembly 130. Spherical connection 232 includes a clamp assembly
234 and a spherical member or ball 236. Ball 236 includes a pair of
shafts 237a, 237b that extend out of opposing sides of ball 236
along an axis 235''.
[0051] Clamp assembly 234 includes a pair of clamp members 234a,
234b that are secured to one another about ball 236 via plurality
of bolts (not shown) extending through aligned apertures 237 in
clamp members 234a, 234b. In addition, second end 128b of shaft 128
is engaged with or coupled to clamp members 234a, 234b such that a
projection of axis 129 is orthogonal to axis 235''. Further, a
shaft 239 is mounted to clamp members 234a, 234b and extends along
a pivot axis 235'. A projection of pivot axis 235' is orthogonal to
axis 235'' and is orthogonal to a projection of axis 129 of shaft
128. Accordingly, axis 235'' and a projection of each of the axes
235' and 129 extend through the center of ball 236. During
operations, the clamp members 234a, 234b may slidingly engage with
outer surface of ball 236 such that clamp members 234a, 234b may
pivot omni-directionally about ball 236 (specifically the center of
ball 236).
[0052] Referring still to FIGS. 6 and 7, shaft 239 is received with
sleeve 142 of sleeve member 140 in the same manner that shaft 139b
is received within sleeve 142 of linking assembly 130. In addition,
shafts 237a, 237b are received within shaft mounts 145 supported on
base 101 such that ball 236 is fixed relative to base 103.
Specifically, ball 236 is not configured to rotate relative to base
101 about shafts 237a, 237b. As with linking assembly 130, in FIG.
6 only one of the shaft mounts 145 (and the associated support on
base 103) is shown so as to better show the details of linking
assembly 230. In other examples, ball 236 may pivot relative to
base 101 about shafts 237a, 237b. Without being limited to this or
any other theory, the rotation of ball 236 about shafts 237a, 237b
may reduce some of the relative movement between ball 236 and clamp
members 234a, 234b and thereby reduce wear, over time, to ball
236.
[0053] Further, the same relationships exist between axes 143',
143'' and axis 115 as described above in the embodiment of FIGS.
2-6. In this embodiment, axes 143', 143'' are parallel to and
radially offset from axis 235'', and axes 235'', 143', 143'' each
lie within vertically oriented planes that extend perpendicularly
to a vertically oriented plane containing axis 115 of output shaft
118. Thus, axes 235'', 143', 143'' each extend in directions that
are perpendicular to the direction of axis 115.
[0054] During operations, as shaft 128 is orbited about axis 115 in
the manner described above, clamp assembly 234 (including clamp
members 234a, 234b) pivots about ball 236. Simultaneously, shaft
239 is driven to rotate along with sleeve member 140 about axis
143' relative to pivoting arm 144, and pivoting arm 144 is pivoted
about each of the axes 143', 143'' relative to sleeve member 140
and carriage 150 in the same manner as previously described above
for linking assembly 130. As a result, carriage 150 and piston 64
are driven to reciprocate in direction 151 (e.g., along track 156)
as previously described.
[0055] During the operational life of a pump assembly 100 (see FIG.
2) utilizing linking assembly 230, the sliding engagement between
ball 236 and clamp members 234a, 234b may cause gradual wear of
ball 236. Due to the omni-directional movement of clamp members
234a, 234b about ball 236, the wear may be relatively uniform so
that the diameter of ball 236 will gradually decrease. In order to
maintain appropriate and desired engagement between ball 236 and
clamp members 234a, 234b, the bolts extending through the aligned
apertures 237 on clamp members 234a, 234b may be engaged or
adjusted as a part of the regular maintenance of pump assembly 100
(see FIG. 2). In addition, in some embodiments, one or more spacers
or shims may be disposed between clamp members 234a, 234b, and as
ball 236 wears (and therefore shrinks) as previously described, the
shims may be replaced and/or removed to provide an appropriate
spacing and engagement between the clamp members 234a, 234b. As a
result, through use of the linking assembly 230 (which includes
spherical connection assembly 232), the operational life of the
original parts making up the linking assembly 230 may be increased
(e.g., particularly ball 236), which thereby reduces the overall
lifetime operational costs for pump assembly 100.
[0056] While exemplary embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the scope or teachings herein. The embodiments
described herein are exemplary only and are not limiting. Many
variations and modifications of the systems, apparatus, and
processes described herein are possible and are within the scope of
the disclosure. Accordingly, the scope of protection is not limited
to the embodiments described herein, but is only limited by the
claims that follow, the scope of which shall include all
equivalents of the subject matter of the claims. Unless expressly
stated otherwise, the steps in a method claim may be performed in
any order. The recitation of identifiers such as (a), (b), (c) or
(1), (2), (3) before steps in a method claim are not intended to
and do not specify a particular order to the steps, but rather are
used to simplify subsequent reference to such steps.
* * * * *